Not long ago, rapid prototypers had one, maybe two materials to work with. Today there are dozens, each with different capabilities. A few are durable enough to make finished consumer and industrial goods. RP firm RedEye RPM, Minneapolis, (redeyerpm.com), works with many materials in their FDM (fused deposition modeling) equipment.

The company lets design firms download cost estimating software that provides quotes for turning concept models into RP or production parts. Then with a purchase order or credit card, RedEye builds the parts in the requested quantity. The only trick is knowing which material to select. RedEye suggests using:

ABS or acrylonitrile butadiene styrene for form, fit, and function checks. It handles details such as snap-fits and ABS parts can be vacuum metalized, electroplated, used in investment casting, as a master for RTV molding, and in vacuum forming.

ABSi is similar to ABS but works well in automotive lenses and other applications that require transparency. ABSi withstands higher impacts than normal ABS.

PC or polycarbonate performs like ABS but has a higher impact strength and can handle higher temperatures. PC is a durable thermoplastic.

PC-ISO or polycarbonate ISO refers to materials meeting ISO 10993-1 and USP Class VI standards. They can be used in medical applications. The materials also meet PC-ISO standards and can be sterilized by either gamma radiation or ethylene oxide. It can be used in pharmaceutical material handling, processing, packaging systems, and surgical instruments.

PC/ABS is a high-performance blend of polycarbonate and ABS. The thermoplastic combines the strength of PC with the flexibility of ABS. It is another high-performance thermoplastic option for rapid manufacturing.

PPSF or polyphenylsulfone is a high-performance material that resists heat and chemicals. Typical applications include automotive and aerospace and those where the part must be functionally tested.